Model 387 Instrument System Service Manual

Transcription

Model 387
Instrument System
Service Manual
Document Number 072-40245
Rev. D
Every effort has been made to keep the information in this document current and accurate as of the date of publication or revision. However, no guarantee is given or implied that the document is error-free or that it is accurate with regard to any
specification. AMETEK Dixson reserves the right to modify product designs and specifications without notice.
Revision Table
Revision
Date
Description
01/27/99
Initial release.
A
05/14/99
Changed all occurrences of “2100” to “387”, and of “self test” to
“initialization”; Fig. 5-22, corrected pin designations on J3 illustration.
B
09/28/99
Added Chapter 6, “Using the Handheld Diagnostic Tool"; removed all references to PTM/VTM replacement and to the ABS
system; improved Pyrometer troubleshooting instructions; updated Warning Messages tables to reflect current configuration;
various other updates and changes resulting from Engineering
Dept. review.
C
03/01/04
Updated and renamed Figure 5-16.
D
01/01/07
Removed contact information.
ii
072-40245 D
Table of Contents
1 Introduction
1.1
1.2
1.3
1.4
1-1
Purpose and Scope . . . . . . . . . . . . .
How To Use This Manual . . . . . . . . . . .
System Components . . . . . . . . . . . .
What Makes the Model 387 Instrument System Different .
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2 Operation
1-1
1-1
1-2
1-2
2-1
2.1
2.2
2.3
2.4
Activating the Instrumentation . . . . .
Select/Reset Switch . . . . . . . .
Speedometer with Integral Message Center .
Using the Speedometer Message Center . .
2.4.1 Clock Operation . . . . . . . . . . . . .
2.4.2 Trip Odometer Operation . . . . . . . .
2.4.3 Clock Alarm Operations. . . . . . . . .
2.5 Warning Alarms . . . . . . . . . .
2.5.1 Red Warning LEDs . . . . . . . . . . .
2.5.2 Vehicle Safety Warning Messages . . .
2.5.3 System Fault Messages . . . . . . . .
3 Functional Description
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2-1
2-1
2-1
2-2
2-2
2-3
2-3
2-3
2-3
2-4
2-4
3-1
3.1 The Interface Module . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.1 Pressure and Vacuum Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.2 Transducer Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.2.1 Pressure Transducer Module......................................................................................3-3
3.1.2.2 Vacuum Transducer Module (VTM) ............................................................................3-4
3.1.3 Vacuum/Pressure and Pressure/Vacuum Transducer Modules . . . . . . . . . . . . . . . . 3-4
3.2 J1708 Data Bus . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Electronic Control Units . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 Speedometer with Integrated Message Center . . . . . . . . . . . . . . . . 3-5
3.4.1 Select and Reset Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4.2 Power Take-Off (PTO) Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4.3 Two-Speed Axle Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5 Diagnostic Capabilities. . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5.1 Power-On Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5.2 Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.6 Private Data Bus . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.6.1 Five-Wire Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.6.2 Two-Inch Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.6.3 J1708 Data Bus and Private-Bus-Driven Gauges . . . . . . . . . . . . . . . . . . . . . . . 3-8
072-40245 D
iii
3.6.4 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.6.4.1 Ammeter........................................................................................................................3-9
3.6.4.2 Voltmeter .....................................................................................................................3-10
3.6.4.3 Pyrometer ....................................................................................................................3-11
3.6.4.4 Transmission and Axle Temperature Gauges................................................................3-12
3.6.4.5 Fuel Level.....................................................................................................................3-13
3.7 Backlighting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
4 Service Procedures
4.1 Some Important Dos and Don’ts . . . .
4.2 Replacing the Speedometer and Tachometer.
4.3 Servicing the Two-Inch Gauges . . . . .
4.3.1 Removal and Reinstallation . . . . . .
4.3.2 Disassembling a Two-Inch Gauge . . .
4.3.3 Reassembling a Two-Inch Gauge . . .
4.4 Reprogramming a Two-Inch Gauge. . . .
4.5 Servicing the Interface Module . . . . .
4.5.1 Removing the Interface Module . . . .
4.5.2 Reinstalling the Interface Module . . .
4.5.3 Reprogramming the Interface Module.
4.6 Spare Parts Listing. . . . . . . . .
4-1
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5 Troubleshooting Procedures
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4-1
4-1
4-2
4-2
4-3
4-4
4-6
4-6
4-6
4-6
4-6
4-7
5-1
5.1 Required Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Troubleshooting Procedure Start Point. . . . . . . . . . . . . . . . . . . . 5-2
5.2.1 The Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Troubleshooting Procedures for Two-Inch Gauges . . . . . . . . . . . . . . . . 5-4
5.3.1 Two-Inch Gauge Fails Initialization, No Pointer Movement, LED Never Lights. . . . . . . . . . 5-5
5.3.2 Two-Inch Gauge Passes Initialization but LED Flashes. . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.2.1 Air and Fuel Pressure Gauges ........................................................................................5-7
5.3.2.2 Temperature Gauges......................................................................................................5-9
5.3.2.3 J1708 Data Bus Gauges ..............................................................................................5-11
5.3.2.4 Vacuum Gauges...........................................................................................................5-11
5.3.2.5 Voltmeter Gauge ..........................................................................................................5-13
5.3.2.6 Ammeter Gauge...........................................................................................................5-14
5.3.2.7 Fuel Level Gauge..........................................................................................................5-16
5.3.2.8 Pyrometer ....................................................................................................................5-17
5.4 Troubleshooting Procedures for the SMC . . . . . . . . . . . . . . . . . . 5-19
5.4.1 SMC Pointer Never Moves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.4.2 Speedometer and Odometers Inaccurate . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.4.3 Speedometer Accurate, Odometer Inaccurate . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.4.4 Odometer Advances When PTO Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.4.5 Speedometer Does Not Change Speed When Two-Speed Axle Engaged . . . . . . . . . . . 5-23
5.4.6 Engine Hours Do Not Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
iv
072-40245 D
5.5 One or More Gauge Pointers Sweep . . . . . . . . . . . . . . . . . . . 5-25
5.5.1 A J1708 Data Bus Gauge Pointer Sweeps . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5.5.2 A Non-J1708 Data Bus Gauge Pointer Sweeps . . . . . . . . . . . . . . . . . . . . . . . 5-26
5.5.3 Several (But Not All) Gauge Pointers Sweep . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.5.4 SMC Pointer and All J1708 Data Bus Gauge Pointers Sweep . . . . . . . . . . . . . . . . 5-27
5.5.5 All J1708 Data Bus Gauge Pointers (Except the SMC Pointer) Sweep . . . . . . . . . . . 5-29
5.5.6 All Gauge Pointers Except the SMC Pointer Sweep . . . . . . . . . . . . . . . . . . . . . 5-30
5.5.7 Only the SMC Pointer Sweeps, and No Messages Appear . . . . . . . . . . . . . . . . . 5-32
5.5.8 SMC Pointer Sweeps, and a NO DATA Message Appears. . . . . . . . . . . . . . . . . . 5-32
5.6 Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5.7 Backlighting Problems . . . . . . . . . . . . . . . . . . . . . . . 5-34
5.7.1 Two-Inch Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
5.7.1.1 One Gauge Has No Backlighting ..............................................................................5-34
5.7.1.2 More Than One Gauge Has No Backlighting ............................................................5-34
5.7.1.3 All Gauges Plus Tachometer Have No Backlighting..................................................5-35
5.7.2 SMC Has No Backlighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5.8 Select/Reset Switches not Working . . . . . . . . . . . . . . . . . . . 5-36
5.9 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
6 Using the Handheld Diagnostic Tool
6-1
6.1 Care and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Reading Engine ECU Gauge Data . . . . . . . . . . . . . . . . . . . . 6-3
6.3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Reading Private Bus Gauge Data. . . . . . . . . . . . . . . . . . . . . 6-6
6.4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5 Viewing Configuration Data . . . . . . . . . . . . . . . . . . . . . . 6-8
6.5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.6 Programming and Verifying Ports 5A and 5B . . . . . . . . . . . . . . . . 6-10
6.6.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.7 Programming the Main Transmission Temperature Warning LED . . . . . . . . . . 6-13
6.7.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.8 HDT Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
072-40245 D
v
List of Illustrations
Figure 1-1
Figure 2-1
Figure 2-2
Figure 3-1
Figure 3-2
Figure 3-3
Figure 3-4
Figure 3-5
Figure 3-6
Figure 3-7
Figure 3-8
Figure 3-9
Figure 3-10
Figure 3-11
Figure 3-12
Figure 4-1
Figure 4-2
Figure 4-3
Figure 4-4
Figure 5-1
Figure 5-2
Figure 5-3
Figure 5-4
Figure 5-5
Figure 5-6
Figure 5-7
Figure 5-8
Figure 5-9
Figure 5-10
Figure 5-11
Figure 5-12
Figure 5-13
Figure 5-14
Figure 5-15
Figure 5-16
Figure 5-17
Figure 5-18
Figure 5-19
Figure 5-20
Figure 5-21
Figure 5-22
Panel and Interface Module . . . . . . . . . . .
System Initialization . . . . . . . . . . . . .
Speedometer Message Center Displays . . . . . . .
Instrumentation Block Diagram . . . . . . . . . .
387 System Interface Module . . . . . . . . . .
Pressure Circuit . . . . . . . . . . . . . . .
Pressure, Vacuum, and Pressure/Vacuum Transducer Modules
387 Speedometer with Message Center . . . . . . .
System Initialization . . . . . . . . . . . . .
J1708 Data Bus Gauges . . . . . . . . . . . .
Ammeter Circuit . . . . . . . . . . . . . . .
Voltmeter Circuit . . . . . . . . . . . . . .
Pyrometer Circuit . . . . . . . . . . . . . .
Axle and Transmission Temperature Circuits. . . . . .
Fuel Level Circuit . . . . . . . . . . . . . .
Two-Inch Gauge Removal and Reinstallation . . . . . .
Scaleplate Alignment . . . . . . . . . . . . .
Two-Inch Gauge Disassembly . . . . . . . . . .
Removing the Interface Module . . . . . . . . . .
Gauge Initialization . . . . . . . . . . . . . .
Checking 2-inch Gauge Power . . . . . . . . . .
Checking Pressure Gauges with Standard Test Gauge . . .
Checking Temperature Sensor Wiring . . . . . . . .
Testing the Air and Fuel Restriction Gauges . . . . . .
Testing the Voltmeter Gauge . . . . . . . . . .
Testing the Ammeter Gauge. . . . . . . . . . .
Testing the Fuel Level Gauges . . . . . . . . . .
Testing the Pyrometer . . . . . . . . . . . .
Testing the Pyrometer (continued) . . . . . . . . .
Troubleshooting SMC Power and Ground . . . . . . .
Troubleshooting the PTO (Power Take-Off) Input . . . .
Troubleshooting the Two-Speed Axle Input . . . . . .
SMC Pointer and All J1708 Data Bus Gauge Pointers Sweep
All J1708 Data Bus Gauge Pointers (except SMC) Sweep .
Checking Power to the Interface Module . . . . . . .
Checking Private Bus Wire Continuity. . . . . . . .
Gauge Backlighting Problem (except SMC) . . . . . .
SMC Backlighting Problem . . . . . . . . . . .
Troubleshooting the Select and Reset Switches. . . . .
Instrumentation Harness Layout . . . . . . . . .
Gauge Connector Wiring . . . . . . . . . . . .
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1-2
2-1
2-2
3-1
3-2
3-3
3-4
3-5
3-6
3-8
3-9
3-10
3-11
3-12
3-13
4-3
4-5
4-5
4-6
5-3
5-5
5-7
5-10
5-12
5-13
5-15
5-16
5-17
5-18
5-20
5-22
5-23
5-28
5-29
5-31
5-31
5-35
5-36
5-37
5-38
5-39
072-40245 D
Figure 5-23
Figure 6-1
Figure 6-2
Figure 6-3
Instrumentation Connector Pinout Diagram . .
Hand-Held Diagnostic Tool. . . . . . . .
Connecting the HDT to the Diagnostic Connector.
Connecting the HDT to the Private Bus . . . .
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5-40
6-2
6-3
6-6
List of Tables
Table 2-1
Table 2-2
Table 4-1
Table 5-1
Table 5-2
Table 5-3
Table 5-4
Table 5-5
Table 5-6
Table 5-7
Table 6-1
072-40245 D
Red Warning LEDs . . . . . . . . .
Vehicle Safety Warning Messages . . . .
387 System Spare Parts . . . . . . .
Troubleshooting Starting Point . . . . .
Two-Inch Gauge Problems. . . . . . .
Problems Indicated by Flashing Gauge LEDs .
SMC Problems . . . . . . . . . .
Problems Indicated by Sweeping Pointer(s) .
Warning Messages . . . . . . . .
System Fault Messages . . . . . . .
HDT Spare Parts . . . . . . . . .
vii
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2-5
2-6
4-7
5-2
5-4
5-6
5-19
5-25
5-33
5-33
6-16
Notes:
viii
072-40245 D
1
Introduction
1.1
Purpose and Scope
The purpose of this manual is to provide Peterbilt with the knowledge required to
produce their own repair procedures. This manual contains the technical repair information necessary to diagnose and repair the Model 387 Instrument System (also referred
to as simply the “instrumentation”). The information in this manual is not proprietary
and can be used as Peterbilt sees fit.
The manual describes how to operate, service, and troubleshoot the instrumentation
installed in vehicles that broadcast engine- and speed-related information over a public data bus (the SAE J1708 data bus). For information about the vehicle’s Electronic Control Unit(s), wiring diagrams, the SAE J1708 data bus, external sensors and other
components that are not part of the instrumentation, please refer to the appropriate
vehicle service documentation.
1.2
How To Use This Manual
The manual is divided into six chapters:
• Introduction - Contains a brief introduction to the product and to the man-
ual itself.
• Operation - A complete operator’s manual. Written for the vehicle opera-
tor, this chapter describes how to use the instrumentation and how to interpret the information it presents. If you are going to operate the vehicle,
you should read and understand the information in this chapter.
• Functional Description - Describes the components that make up the in-
strumentation and how they communicate with other systems in the vehicle. An understanding of the information in this chapter will help you
diagnose and find problems in the instrumentation. If you are going to service the instrumentation, you should read and understand the information
in this chapter.
• Service - Describes how to remove, disassemble, and reinstall the compo-
nents of the instrumentation. It contains a spare parts list, and other important information. Do not service the instrumentation until you have read
and understand the information in this chapter.
• Troubleshooting - Provides detailed troubleshooting information that will
help you identify faulty components within the instrumentation.
• Using the Handheld Diagnostic Tool (HDT) - Describes the operation of
the handheld diagnostic tool used to help diagnose problems with the
instrumentation.
072-40245 D
1-1
Introduction
1.3
System Components
The instrumentation consists of a 33 8-inch speedometer with an integrated message center, a 33 8-inch tachometer, several 2-inch gauges, a Select/Reset
switch, and a remotely mounted Interface Module. Figure 1-1 shows how a
typical system with four 2-inch gauges might look, along with an Interface
Module.
Figure 1-1
1.4
Panel and Interface Module
What Makes the Model 387 Instrument System Different
In conventional instrumentation, each electrical gauge is connected to a sensor by a
signal wire and a return wire. Additional wires for illumination, power, ground and
warning lights could total as many as six wires per gauge. Thus, a panel with 10
gauges plus a speedometer and a tachometer could require up to 60 separate wires.
By comparison, the Model 387 Instrument System uses a single 5-wire cable to connect all the gauges. This significantly reduces the number of wires behind the instrument panel and makes the system much easier to troubleshoot and service.
The instrumentation is easy to repair. The 2-inch gauges can be disconnected, removed from the panel, disassembled, reassembled, and reinstalled without tools, and they
are maintenance-free.
With the exception of the scaleplate, all 2-inch gauges are identical. Each scaleplate is
coded and when installed in the gauge, configures the gauge to the function shown
on the scaleplate. This reduces the spare parts inventory by requiring only a few
blank gauges and a supply of inexpensive scaleplates rather than a complete spare
gauge of each type.
The instrumentation can also display warning messages and audible alarms, and has
built-in diagnostic capabilities to help diagnose problems.
Introduction
1-2
072-40245 D
2
Operation
2.1
Activating the Instrumentation
Turning on the ignition activates the instrumentation and starts the initialization described in Figure 2-1.
Figure 2-1
System Initialization
Service the vehicle if any of the following conditions occur after the initialization:
• The speedometer or tachometer pointer sweeps back and forth in a wind-
shield wiper motion.
• A 2-inch gauge pointer sweeps back and forth in a windshield wiper mo-
tion and stops at a 10:00 position with its red LED on.
• A 2-inch gauge pointer stays at a 7:00 position and its red LED flashes.
• A 2-inch gauge pointer goes to and remains at a 12:00 position with its red
LED on.
2.2
Select/Reset Switch
A Select/Reset switch on the dash allows you to select, set, and reset message center
displays. It also allows you to scroll through active system warning messages.
2.3
Speedometer with Integral Message Center
The speedometer and its message center together are called the SMC. The SMC normally displays road speed and the odometer reading. The SMC can also display other
functions as shown in Figure 2-2.
072-40245 D
2-1
Operation
To view a different function, press and release the Select switch until the desired function appears.
Figure 2-2
Speedometer Message Center Displays
The message center goes into a “sleep” mode (i.e. goes blank) when the ignition is
turned off. Each time you press the Select switch, the message center is “awakened”
for 10 seconds. This allows you to scroll through the different functions.
If a warning alarm is triggered, a warning message will override all other displays until the condition that caused the warning alarm is corrected. Some warning alarms include an audible warning. Warning alarms are described in detail in Section 2.5.
2.4
Using the Speedometer Message Center
2.4.1
Clock Operation
To display the clock time, press and release the Select switch until the clock is
displayed.
To change the clock time -
Operation
1.
Press and release the Reset switch. The Hours display will flash, indicating
the value can be changed.
2.
Press the Select switch to change the Hours value, or press the Reset switch
to accept the displayed value and enable the Minutes value to be changed. To
change from AM to PM, scroll through 12 hours.
3.
When the Minutes value is flashing, press the Select switch to change the
value, or press the Reset switch to accept the displayed value and exit the
Change Time function. Scrolling the Minutes value past 59 will not change
the Hours value.
2-2
072-40245 D
2.4.2
Trip Odometer Operation
To display the Trip 1 or 2 Odometer, press and release the Select switch until
XXXXT1 or XXXXT2 is displayed (XXXX = the actual mileage reading).
To reset a trip odometer to zero -
2.4.3
1.
Display the odometer to be reset (Trip 1 or Trip 2)
2.
Press and hold the Reset switch for 3 seconds.
Clock Alarm Operations
To display the alarm time, press and release the Select switch until an AL appears along with a time value.
To change the alarm time 1.
Press and release the Reset switch. The Hours digits will begin to flash, indicating the values can be changed.
2.
Press the Select switch to change the Hours value, or press the Reset switch
to accept the displayed value and enable the Minutes value to be changed. To
change from AM to PM, scroll through 12 hours.
3.
When the Minutes value is flashing, press the Select switch to change the
value. Scrolling the Minutes value past 59 will not change the Hours value.
4.
Press the Reset switch to accept the displayed value and exit the Change
Alarm Time function. This also activates the alarm and an asterisk ( * ) will
appear in the first digit of the Clock display to indicate the alarm is on.
To activate or deactivate the alarm tone, from any display, press and hold the Select switch longer than three seconds.
To silence the alarm tone while it is sounding, press and release the Select
switch while the alarm is sounding.
2.5
Warning Alarms
A warning alarm indicates that some condition in the vehicle requires attention.
A warning alarm can be indicated in the following ways:
• Red warning LEDs in the 2-inch gauges
• Vehicle safety warning messages in the SMC
• System fault warning messages in the SMC
A warning alarm will continue until the condition that caused it is corrected. At that
time, the SMC will display a Reset message for 10 seconds, and the warning indications will cease. Pressing the Reset switch clears the Reset message sooner.
2.5.1
Red Warning LEDs
Table 2-1 on page 2-5 lists the conditions which light the red warning LEDs. Some
of the LEDs light when the Interface Module receives the appropriate message
072-40245 D
2-3
Operation
over the J1708 data bus. Other LEDs light as determined by Interface Module programming, and some warning LEDs are not used. Column 3 lists the condition
that causes the warning LED to light.
You cannot dismiss or override red warning LED indications. A red warning LED
will remain on until the condition causing it is corrected.
Note - Not all gauges listed are currently available.
2.5.2
Vehicle Safety Warning Messages
Messages advising of unsafe operating conditions can appear in the SMC. Examples are a major engine or transmission problem (low oil pressure, high temperature, low coolant level) and a problem with the brake safety (low air pressure). An
audible alarm will accompany these warning messages.
Vehicle safety warning messages are listed in Table 2-2 on page 2-6. Column 1
shows the warning message as it appears in the SMC, and column 2 identifies its
meaning. Column 3 identifies the gauge whose red warning LED lights. Column
4 shows the associated Reset message.
You can temporarily override vehicle safety warning messages two ways:
2.5.3
1.
Press the Reset switch for 3 seconds. This will dismiss the message and silence the buzzer. If an active alarm still exists, the message and buzzer will return.
2.
Press the Reset switch for 1 second, then press the Select switch to display
any other function. The warning message will disappear for 60 seconds. It
will then reappear and remain until the condition causing it is corrected. The
audible alarm will continue to sound.
System Fault Messages
A system fault message indicates a problem exists with the Model 387 Instrument System that does not directly affect vehicle safety. These occur when the ignition is first
switched on. The messages are:
IM CAL, IM CFG, IM DIAG, IM LIN, IM SLFT, ODO ERR, NO DATA, SMC MEM.
System fault messages are detected by the Interface Module or the SMC. No gauge
LED is associated with them, no audible warning will sound, and no Reset message
will appear.
The NO DATA message can occur any time, not just during System Initialization.
Operation
2-4
072-40245 D
Gauge
Indication When Led Is On Activating Condition
Air Cleaner Restriction
Clogged
More than 25“ of water (H2O)
Air Tank 1
Too low
Less than 66 psi
Air Tank 2
Too low
Less than 66 psi
Air Starter Air Pressure
No indication
Not activated
Ammeter
Incorrect discharge rate
>25 amps when RPM <1200, or
>2 amps when RPM >1200
Auxiliary Transmission Oil Temp
Too high
Higher than 230° F
Brake Saver Application Air Pressure
No indication
Not activated
Brake Saver Oil Temp
Too high
Higher than 230° F
Center Drive Axle Oil Temp
Too high
Higher than 230° F
Engine Load
No indication
Not activated
Engine Oil Pressure
Too low
Engine ECU
Engine Oil Temperature
Too high
Engine ECU
Front Drive Axle Oil Temp
Too high
Higher than 230° F
Fuel Filter Restriction
Clogged
More than 7“ of mercury
Fuel Level (left, right, or main tank)
Low fuel
1
Fuel Pressure
No indication
Not activated
Load Gauge Air Pressure
No indication
Not activated
Main Transmission Oil Temp
Too high
Programmable
Manifold Boost
No indication
Not activated
Pusher Suspension Air Pressure
No indication
Not activated
Pyrometer
Too high
Higher than 1200° F
Tractor Brake Applic. Air Pressure
No indication
Not activated
Rear Drive Axle Oil Temp
Too high
Higher than 230° F
Tag Suspension Air Pressure
No indication
Not activated
Trailer Brake Applic. Air Pressure
No indication
Not activated
Voltmeter
Too low or too high
>15 volts or <10 volts
Engine Coolant Temp
Too high
Engine ECU
6X6 Front Drive Axle Oil Temp
Too high
Higher than 230° F
Air Deflector Position
No indication
Not activated
Transfer Case Oil Temp
Too high
Higher than 230° F
Table 2-1
072-40245 D
8
tank or less
Red Warning LEDs
2-5
Operation
Warning
Message
Condition
Associated
Gauge LED
Reset
Message
H2O TMP
Coolant temperature high
Water Temperature
H2OT OK
LOW AIR1
Air tank #1 pressure low
Primary Air Pressure
AIR1 OK
LOW AIR2
Air tank #2 pressure low
Secondary Air Pressure
AIR2 OK
OILPRES
Engine oil pressure low
Engine Oil Pressure
OIL OK
OIL TEMP
Engine oil temperature high
Engine Oil Temperature
OILT OK
TRANTMP
Main transmission oil
temperature high
Main Transmission Oil Tem- TRAN OK
perature
CAUTION! If a message that is not listed in this table appears, do not ignore it. The vehicle should
be serviced regardless of the message that appears.
Table 2-2
Operation
Vehicle Safety Warning Messages
2-6
072-40245 D
3
Functional Description
This section describes the instrumentation on a functional level. It is not necessary to
read this section to troubleshoot and service the system. It is intended to provide a
more detailed understanding of how the system works. Figure 3-1 illustrates the major components and signal flow.
Note - Throughout this manual, the terms “public data bus” or “public bus” refer
specifically to the J1708 data bus.
Figure 3-1
Caution!
072-40245 D
Instrumentation Block Diagram
Never store gauges face down. The gauge meter movements use an oil damping
suspension. If a gauge is left face-down longer than 15 minutes, the oil may
begin to run out. This causes inaccurate gauge readings, premature gauge
failure, and voids the warranty.
3-1
3.1
The Interface Module
The Interface Module controls the instrumentation by collecting information
from various sources and converting that information into gauge pointer information which it then sends to the gauges. It is an environmentally sealed unit
and it is usually mounted beneath the cab and against the frame rail. It is connected to the J1708 data bus, and to switches, sensors and pressure/vacuum hoses
throughout the vehicle.
Figure 3-2
387 System Interface Module
All gauge and display information is gathered by the Interface Module except:
• Road Speed and Engine Hours - Road Speed and Engine Hours messages
are sent directly to the SMC over the J1708 data bus. The SMC also uses
road speed messages to compute mileage and display it on the odometers.
• Select and Reset Input - These switched inputs are applied directly to the
SMC.
• Clocks - Clock and Alarm Clock information is generated within the SMC.
• Gauge Backlighting - Power for the gauge backlighting comes from an ex-
ternal dimming control and completely bypasses the Interface Module.
3.1.1
Pressure and Vacuum Inputs
Hose connections to the transducer modules provide pressure or vacuum to the Interface Module. The Interface Module converts the pressure and vacuum signals to
data and places that data on the private data bus to drive the pressure gauges. Connections are shown in Figure 3-3.
3-2
072-40245 D
If an Air Filter Restriction gauge is present, its input must be connected to port 5A. If a
Fuel Filter Restriction gauge is present, its input must be connected to port 5B. Other
pressure inputs are connected to port 5A or 5B, whichever is available depending
upon whether an Air Filter or a Fuel Filter Restriction gauge is present.
Whenever the Interface Module is replaced, you must reprogram it recognize the
pressure gauges. You do not need to reprogram it when replacing defective gauges.
Figure 3-3
3.1.2
Pressure Circuit
Transducer Modules
Four different transducer modules are available. All modules consist of pressure or
vacuum transducers (or both) mounted in a common thermoplastic base inside a
metal housing. Each transducer converts pressure (or vacuum) into a DC voltage that
can be used by the Interface Module.
Transducer modules cannot be replaced in the field.
3.1.2.1
Pressure Transducer Module
A pressure transducer module (PTM) contains two identical pressure transducers,
each capable of handling up to 150 psi. It can be connected to air, fuel, or oil pressure
inputs. It is mounted at port 1A/1B and connected to Air Tank 1 and Air Tank 2 air
pressure. A second PTM may also be mounted at port 5A/5B and connect to additional pressure sources. See Figure 3-4 on page 3-4.
072-40245 D
3-3
Figure 3-4
Pressure, Vacuum, and Pressure/Vacuum Transducer Modules
3.1.2.2
Vacuum Transducer Module (VTM)
A vacuum transducer module (VTM) contains two vacuum transducers. The VTM is
used for the Air Filter Restriction and Fuel Filter Restriction gauges. The VTM must be
mounted at port 5A/5B only.
The vacuum transducers are not identical. The Air Filter Restriction end must go to
port 5A, and the Fuel Filter Restriction end must go to port 5B as shown in Figure 3-4.
3.1.3
Vacuum/Pressure and Pressure/Vacuum Transducer Modules
Two types of combination modules are available. One type contains a pressure transducer and an Air Restriction transducer; the other type contains a pressure transducer
and a Fuel Filter Restriction transducer. Combination modules are not interchangeable
and are mounted at port 5A/5B. If used, the Air Filter Restriction end must go to port
5A, and the Fuel Filter Restriction end must go to port 5B as shown in Figure 3-4.
CAUTION -
3.2
The sudden application of pressure to transducer modules can destroy them
and void their warranties. Always apply pressure gradually and at a rate that
does not exceed 150 PSI per second.
J1708 Data Bus
The J1708 data bus is a public data bus consisting of a pair of twisted-wires. It allows
electronic devices and other equipment in the vehicle to send and receive data. The
two wires making up the J1708 data bus are part of the vehicle’s wiring harness. Because it connects to many different components in widely separated locations, a problem with the data bus or with one of the component’s connected to it can sometimes
be hard to isolate. For a complete description of the J1708 data bus and data format,
refer to SAE J1708 document Standard For Data Communications Interface and to SAE
J1587 document, Standard For Data Interchange.
3-4
072-40245 D
3.3
Electronic Control Units
Electronic Control Units (sometimes called ECUs) are computerized units that
control a particular vehicle subsystem. For example, an Engine ECU helps maximize engine efficiency, a Transmission ECU helps control transmission operation, and an ABS (Anti-lock Brake System) ECU maximizes braking performance.
An ECU designed for one system cannot be interchanged with an ECU designed
for another.
ECUs are connected to the J1708 data bus. They send and receive data to each other
and to other devices on the bus. Each ECU is programmed to respond to and to generate specific data.
3.4
Speedometer with Integrated Message Center
The SMC is connected to the J1708 data bus and responds to data from the Engine
ECU. It uses road speed data from the Engine ECU to calculate its own pointer information. It also responds to other data on the J1708 data bus and can display it on the
Message Center. Examples are engine hours and diagnostic messages. The SMC has
no calibration switches and requires no programming. See Figure 3-5.
Figure 3-5
387 Speedometer with Message Center
The SMC calculates and stores its own odometer, trip odometer, clock and alarm clock
information independent of the Interface Module, and has a built-in audible alarm. The
SMC automatically displays warning messages when an alarm condition is detected.
072-40245 D
3-5
3.4.1
Select and Reset Switches
The Select and Reset switches select, set, and reset the clock, the alarm clock, and the
trip odometers. Their inputs are connected to the SMC by a 4-pin connector on the
rear of the speedometer housing.
If these inputs are not connected, the SMC will display odometer information and
warning messages only.
3.4.2
Power Take-Off (PTO) Input
This input provides a ground from a switch in the PTO system to the SMC. It prevents the SMC from accumulating miles when the PTO system is in use and the vehicle is not moving.
3.4.3
Two-Speed Axle Input
This input to the back of the SMC is a positive voltage that comes from the 2-speed
axle actuator on the gearshift lever. When the 2-speed axle is engaged, this input
causes the SMC to reduce the road speed indication by a factor of 0.73 to 1.
3.5
Diagnostic Capabilities
The instrumentation has a built-in initialization routine and several diagnostic capabilities that can indicate if the system is functioning properly or if a problem exists
with it or with the system inputs.
3.5.1
Power-On Initialization
When the ignition is first turned on the instrumentation performs an initialization to
verify correct operation. The initialization is described in Figure 3-6.
Figure 3-6
System Initialization
3-6
072-40245 D
3.5.2
Diagnostic Connector
The diagnostic connector allows test equipment such as the Handheld Diagnostic
Tool described in Chapter 6 to be connected to the J1708 data bus. The diagnostic connector is usually located underneath the driver’s side of the dashboard.
Note - The diagnostic connector is not part of the instrumentation and is mentioned
for reference only.
3.6
Private Data Bus
The private data bus connects the Interface Module to the tachometer and the 2-inch
gauges. It carries data from the Interface Module to the tachometer and 2-inch
gauges. The private data bus consists of a pair of wires in the 5-wire cable assemblies.
It is not connected to the J1708 data bus.
3.6.1
Five-Wire Cable Assemblies
Identically wired 5-wire cable assemblies make up the private data bus that connects
the tachometer and 2-inch gauges. These cable assemblies carry power, ground,
backlight power and private data bus signals from one gauge to the next. Their 5-pin
plugs are polarized and cannot be plugged in backwards. Identical pinouts allow either end to be plugged into either of two identical sockets on the back of the gauges.
The plugs are held in place by a locking tab. Depressing the locking tab lets you remove the connector from the gauge.
3.6.2
Two-Inch Gauges
Each 2-inch gauge consists of a printed circuit board and meter assembly, and a
scaleplate with programming tab. These parts are mounted together with a glass faceplate and a sealing ring in a plastic, twist-apart housing. Figure 4-3 on page 4-5 shows
how these parts are assembled.
The printed circuit board has a red warning LED, two LEDs for backlighting, a microprocessor that converts messages from the private data bus into LED and pointer information, a pair of private data bus connectors, and small 5-pin contact assembly
that accepts the programming tab on the scaleplate.
The scaleplate’s programming tab automatically configures a gauge to the function
shown on the scaleplate. Holes in the tab perform the actual programming by allowing certain contact pins to make contact with the circuit board. A microprocessor on
each gauge circuit board converts the private data bus messages into meter drive signals. Figure 4-2 on page 4-5 shows the contact assembly and the placement of the tab.
072-40245 D
3-7
3.6.3
J1708 Data Bus and Private-Bus-Driven Gauges
The sensors for the Tachometer, Engine Oil Pressure, Engine Coolant, Engine Oil
Temperature, Engine Load %, and Manifold Boost gauges are connected to the Engine ECU. The Engine ECU converts these sensor inputs into data which it sends to
the Interface Module over the J1708 data bus. For that reason, these gauges are called
J1708 data bus gauges. J1708 data bus gauges and connections are shown in Figure 3-7.
Figure 3-7
J1708 Data Bus Gauges
The axle and transmission temperature sensors, the ammeter, fuel level and pyrometer sensors, and pressure/vacuum inputs are connected directly to the Interface Module and are referred to as private-bus-driven gauges.
3.6.4
Tachometer
The tachometer is similar in construction to the 2-inch gauges except that it is larger
and is not programmable.
Engine speed data originates at a sensor mounted on the engine. The Engine ECU
receives the data, converts it into rpm data and sends it over the J1708 data bus. The
Interface Module reads the rpm data on the J1708 data bus and converts it into tachometer data which it places on the private data bus. The tachometer receives the data
and converts it into pointer drive signals. Connections are shown in Figure 3-7.
3-8
072-40245 D
3.6.4.1
Ammeter
The signal for the ammeter begins at a sense wire coiled up in the battery box (between the battery’s positive terminal and the megafuse leading to the alternator). As
current from the vehicle’s charging system flows through the sense wire, a voltage of
a few millivolts is generated. This voltage is applied to the Interface Module which
converts it into ammeter messages on the private data bus.
If the system is charging, the positive voltage at the sense wire causes the ammeter to
read in the positive ( + ) area. If the system is discharging, the sense wire voltage goes
negative and causes the ammeter to read in the negative ( – ) area. See Figure 3-8 for the
actual wire connections.
Figure 3-8
072-40245 D
Ammeter Circuit
3-9
3.6.4.2
Voltmeter
Battery voltage is fed to the Interface Module through the ignition switch. The Interface Module converts the voltage into data that it places on the private data bus. See
Figure 3-9 for the actual wire connections.
Figure 3-9
Voltmeter Circuit
3-10
072-40245 D
3.6.4.3
Pyrometer
The signal for the pyrometer begins at a Type K thermocouple that is mounted in the
exhaust stream and connected to the Interface Module. A thermocouple creates a
small voltage (less than 33 millivolts) that changes depending upon its temperature.
As the exhaust temperature rises, the thermocouple output voltage increases. The Interface Module converts the voltage into data that it places on the private data bus.
Connections are shown in Figure 3-10.
Figure 3-10
072-40245 D
Pyrometer Circuit
3-11
3.6.4.4
Transmission and Axle Temperature Gauges
Temperature senders installed in the appropriate axle or transmission housing and
connected to the Interface Module sense the temperature of the gear oil. Each sender
contains a thermistor whose value decreases as the temperature increases. The Interface Module converts the thermistor resistance and into data that it places on the private data bus. Connections are shown in Figure 3-11.
Figure 3-11
Axle and Transmission Temperature Circuits
3-12
072-40245 D
3.6.4.5
Fuel Level
The signal for the fuel level comes from a sender unit that is mounted inside the fuel
tank and connected to the Interface Module. The sender unit contains a float device
attached to a variable resistor. As the fuel level drops, the float drops and the resistance of the variable resistor increases. The Interface Module converts the resistance
into data that it places on the private data bus. Connections are shown in Figure 3-12.
Figure 3-12
3.7
Fuel Level Circuit
Backlighting
Light-emitting diodes (LEDs) permanently mounted inside the gauge provide
backlighting. The LEDs are not replaceable. Theyreceive power from a dimming control located on the vehicle dash, and that power is passed from one gauge to the next
through the 5-wire cable assemblies. If a gauge’s backlighting fails, the gauge must be
replaced. More information is available in Chapter 5.
Backlight power for the SMC comes from the same source used for the gauge
backlighting.
072-40245 D
3-13
Notes:
3-14
072-40245 D
4
Service Procedures
All components of the instrumentation are easily replaceable in the field. This chapter
describes the correct method of removing and replacing the system’s components.
For troubleshooting information, see Chapter 5. For a functional description of the instrument system, see Chapter 3.
Note - None of the instrumentation’s components can be repaired in the field. Replace them if defective. Opening any of the components voids the warranty.
The 2-inch gauges may be opened to replace scaleplates without affecting the
warranty.
4.1
4.2
Some Important Dos and Don’ts
Do—
Don’t—
Always unplug all connectors from the
Interface Module before performing any
welding on the vehicle. Extensive and
expensive electronic damage may result
if the wiring is left connected.
Do not splice into the data bus at any
time. Incorrect data and false readings
can result.
The warning lights and the backlighting
in the gauges are LEDs. If a gauge LED is
defective, replace the entire gauge.
Do not open or attempt to service the
speedometer, tachometer, or Interface
Module or the warranty will be
voided.
Store or hold gauges in their normal operating position or face up to prevent the
gauge dampening fluid from leaking
out.
Do not store or otherwise leave any
gauge face down longer than 15 minutes.
Apply pressure or vacuum slowly to
transducer modules.
Do not apply pressure to transducer
modules at a rate that exceeds 150 PSI
per second.
Replacing the Speedometer and Tachometer
Note - The SMC calculates and stores odometer and trip odometer data. If the SMC
is replaced with one from another vehicle, the odometer will reflect the other
vehicle’s accumulated mileage. If a factory-new speedometer is installed, the
odometer will read zero.
072-40245 D
4-1
Service Procedures
The SMC and tachometer are mounted using standard U-brackets. To replace the
SMC or tachometer:
4.3
1.
Unplug the connectors from the rear of the gauge by depressing their tabs
while pulling the connector straight out.
2.
Remove the two nuts and lock washers holding the U-bracket and remove
the U-bracket.
3.
Remove the instrument from the front of the panel.
4.
To reinstall, place the instrument through the front of the panel and line up
the alignment tab at the bottom with the cutout notch in the mounting hole.
5.
Attach the U-bracket to the instrument and secure with the nuts and lock
washers.
6.
Reattach the connectors.
Servicing the Two-Inch Gauges
4.3.1
Removal and Reinstallation
Follow the instructions in Figure 4-1 to remove and reinstall the 2-inch gauges.
Service Procedures
4-2
072-40245 D
Figure 4-1
Two-Inch Gauge Removal and Reinstallation
Note - If installing an additional pressure gauge, ensure that the correct Vacuum or
Pressure Transducer Modules are installed on the Interface Module, and that
the Interface Module has been programmed to recognize the new gauge.
4.3.2
072-40245 D
Disassembling a Two-Inch Gauge
1.
With your hand, turn the bezel counter-clockwise about 1 8 turn and remove
the bezel, glass, gasket, and mask ring. This requires a fair amount of initial
force.
2.
Gently slide the gauge out of its housing.
3.
Gently pull the scaleplate programming tab out from under the connector on
the printed circuit board.
4.
Remove the scaleplate by allowing the gauge pointer to pass through the cut
on the scaleplate.
4-3
Service Procedures
4.3.3
Service Procedures
Reassembling a Two-Inch Gauge
1.
Attach the scaleplate to the gauge as shown in Figure 4-2.
2.
Referring to Figure 4-3, insert the gauge body into the housing. Ensure the
connector extends through the rear of the housing. The three round notches
around the edge of the printed circuit board fit over the round guides on the
inside of the housing. The gauge is correctly inserted when the two round
notches in the front of the gauge fit over the two round guides on the inside
of the housing and the connector extends slightly out the rear of the housing.
3.
Hold the gauge and housing face up. Line up the hole in the finger of the
mask ring over the warning LED in the gauge body and place the mask ring
down over the scaleplate. When the mask ring is correctly installed, the two
round notches on the outside will mate with the two guides on the inside of the
housing.
4.
Center the gasket over the mask ring.
5.
Center the glass faceplate over the gasket.
6.
Line up the tab on the back of the bezel with the cut-out in the housing, then
twist the bezel 1 8 turn clockwise until it clicks into place.
4-4
072-40245 D
072-40245 D
Figure 4-2
Scaleplate Alignment
Figure 4-3
Two-Inch Gauge Disassembly
4-5
Service Procedures
4.4
Reprogramming a Two-Inch Gauge
Two-inch gauges are identical in design and hardware with the exception of their scaleplates. This allows any 2-inch gauge to serve a variety of functions simply by changing its
scaleplate. To reprogram a 2-inch gauge to a different function, simply attach the appropriate scaleplate as shown in Figure 4-2.
4.5
Servicing the Interface Module
4.5.1
Removing the Interface Module
To remove the Interface Module, follow the instructions in Figure 4-4.
Figure 4-4
4.5.2
4.5.3
Removing the Interface Module
Reinstalling the Interface Module
1.
Position the Interface Module in its mounting location and secure it using the
two fasteners. Do not tighten the mounting fasteners more than 32 inchpounds.
2.
Reconnect J3 and J4.
3.
Reconnect the air vent hose and the vacuum/pressure hoses to the Interface
Module as specified by the vehicle manufacturer.
Reprogramming the Interface Module
The Interface Module must be told which pressure gauges are present at ports 5A and
5B, and what kind of transmission is installed in the vehicle. This is done using the
HDT as described in Chapter 6. In addition, the Interface Module must be reprogrammed whenever it is replaced.
Service Procedures
4-6
072-40245 D
4.6
Spare Parts Listing
Part Number
Description
17-05068-001
Interface Module (PPPP) with modules
17-05068-002
Interface Module (PPVV) with modules
17-05068-003
Interface Module (PPVP) with modules
17-05068-004
Interface Module (PPPV) with modules
17-05068-005
Interface Module (PPCC) with one pressure module
17-05066-001
SMC, MPH/kph, black bezel
17-05066-002
SMC, MPH/kph, satin bezel
17-05066-003
SMC, KPH/mph, black bezel
17-05066-004
SMC, KPH/mph, satin bezel
17-05067-007
Tachometer, black bezel
17-05067-002
Tachometer, satin bezel
00049861
2-inch general gauge, black bezel
00049862
2-inch general gauge, satin bezel
Call factory for 2-inch gauge scaleplates
part number
Note PP = Pressure/Pressure; PV = Pressure/Fuel Restriction; VP = Air Restriction/
Pressure; VV = Air Restriction/Fuel Restriction; CC = Cover Plate
Table 4-1
072-40245 D
387 System Spare Parts
4-7
Service Procedures
Notes:
Service Procedures
4-8
072-40245 D
5.5
One or More Gauge Pointers Sweep
Run the initialization again and observe all gauge pointers. Then find the symptom in Table 5-5 that best describes what you see and follow the instructions.
Symptom
Probable Cause
Action
A J1708 data bus gauge* pointer sweeps.
No data from Engine
ECU.
Go to Section 5.5.1 on
page 5-27.
A non-J1708 data bus gauge pointer
sweeps.
Interface Module incor- Go to Section 5.5.2 on
rectly programmed.
page 5-27.
Several (but not all) gauge pointers sweep. Private data bus wires
open between the
gauges.
page 5-28.
The SMC and all J1708 data bus gauge*
pointers sweep, SMC displays NO DATA
(may take a couple of minutes to appear).
Defective part on J1708 Go to Section 5.5.4 on
data bus.
page 5-28.
All J1708 data bus gauge pointers*
except the SMC pointer sweep.
J1708 data bus open be- Go to Section 5.5.5 on
tween Engine ECU and page 5-30.
Interface Module.
All gauge pointers except the SMC pointer
sweep.
Private data bus open; Go to Section 5.5.6 on
defective component
page 5-31.
on private data bus.
Only the SMC pointer sweeps, and no
messages appear.
No speed data from
Engine ECU.
SMC pointer sweeps, SMC displays NO
DATA (may take a couple of minutes to
appear).
J1708 data bus open be- Go to Section 5.5.8.
tween Engine ECU and
SMC.
page 5-33.
* Notes: J1708 data bus gauges are gauges whose data is sent from the Engine ECU to the Interface
Module over the J1708 data bus. The SMC, Tachometer, Engine Oil Temperature, Engine Oil Pressure, Engine Coolant Temperature, Manifold Boost, and Engine Load % gauges are all J1708 data bus
gauges
Data for the remaining gauges is sent directly to the Interface Module through connectors J3 and J4
(various temperature inputs, fuel level, etc.) or through direct connections to the pressure and vacuum
transducer modules.
Table 5-5
Troubleshooting Procedures
Problems Indicated by Sweeping Pointer(s)
5-26
072-40245 C
5.5.1
A J1708 Data Bus Gauge Pointer Sweeps
Probable Cause - No data from Engine ECU.
Procedure:
1.
Start the vehicle’s engine and use the Select button to scroll through the SMC
messages. If DIAG appears, the Interface Module is defective and must be replaced. If not, go to the next step.
2.
Connect the HDT to the rear of any 2-inch gauge. Usually the last gauge in
the series has an unused connector.
3.
Use the HDT to verify data for the suspect gauge is present on the private
data bus.
a.
If data for that gauge is present on the private data bus, remove the
gauge and verify that the gauge scaleplate is correctly installed; if the
scaleplate is correctly installed, replace the defective gauge.
b.
If data for that gauge is not present on the private data bus, disconnect the HDT from the 2-inch gauge and connect it to the diagnostic
connector to see if the Engine ECU is placing data for the gauge on
the J1708 data bus.
c.
If data for that gauge is present on the J1708 data bus, replace the Interface Module.
d. If data for that gauge is not present on the J1708 data bus, check the
Engine ECU according to the manufacturer’s diagnostic procedures.
5.5.2
A Non-J1708 Data Bus Gauge Pointer Sweeps
Probable Cause - Interface Module incorrectly programmed.
Procedure:
072-40245 D
1.
Start the vehicle’s engine and use the Select button to scroll through the SMC
messages. If DIAG appears, the Interface Module is defective and must be replaced. If not, go to the next step.
2.
Connect the HDT to the rear of any 2-inch gauge. Usually the last gauge in
the series has an unused connector.
3.
Use the HDT to verify data for the suspect gauge is present on the private
data bus.
a.
If data for that gauge is present on the private data bus, remove the
gauge and verify that the gauge scaleplate is correctly installed; if the
scaleplate is correctly installed, replace the defective gauge.
b.
If the gauge is not a pressure gauge and no data for it is present on
the private data bus, replace the Interface Module.
c.
If the gauge is a pressure gauge and data for that gauge is not present
on the private data bus, connect the HDT to the diagnostic connector
5-27
and verify the Interface Module is correctly configured for that
gauge. If not, reconfigure as appropriate.
d. If the Interface Module is correctly programmed for that pressure
gauge and data is still not present on the private data bus, replace the
Interface Module.
5.5.3
Several (But Not All) Gauge Pointers Sweep
Probable Cause - The private data bus + or – wires are open between the gauges.
Procedure:
5.5.4
1.
Locate the first gauge in the daisy chain that is not working and verify its
connectors are fully engaged.
2.
Unplug both connectors and inspect their pins and the gauge receptacle for
bent or missing pins. Replace the gauge or the 5-wire cable assembly if damaged.
3.
If no damage is evident, replace the 5-wire cable assembly that connects the
first defective gauge to the last gauge on the daisy chain that works.
4.
If the problem still is not corrected, then the last working gauge on the daisy
chain could have an internally damaged connector. Replace that gauge.
Symptoms - The SMC pointer and the pointers of all public bus gauges sweep; the
SMC displays NO DATA.
Note:
It can take as long as 2 1 2 minutes to display NO DATA.
Probable Cause - The J1708 data bus from the Engine ECU to the Interface Module
and the SMC is open (broken wire or connector pin); defective Interface Module; defective SMC; defective Engine ECU or other device connected to the J1708 data bus.
Procedure: (see Figure 5-14 on page 5-29.)
1.
Perform the checks in Figure 5-14 on page 5-29. If the reading is less than
about 10 ohms, another device using the J1708 data bus (SMC, Interface Module, ABS, Transmission or HVAC ECU, satellite communications devices, etc.)
could be defective and interfering with bus communications. Continue with
the next step.
2.
To find which device may be interfering with data bus communications,
switch the ignition off and disconnect the devices from the J1708 data bus as
follows:
a.
Locate the splice block behind the glove box and unplug all devices
at the splice block except the Engine ECU.
b.
Disconnect the Interface Module by unplugging 10-pin connector J3
at the module.
5-28
072-40245 D
c.
Figure 5-14
072-40245 D
Disconnect the SMC by unplugging the six-pin connector from the
rear of the SMC.
3.
After disconnecting all devices except the Engine ECU, use the engine manufacturer’s diagnostic procedures to verify the Engine ECU is working properly.
4.
If the Engine ECU is good, reconnect each device one at a time, verifying the
Engine ECU is still working after each device is connected.
5.
If the Engine ECU quits working after a particular device is connected, replace that device.
5-29
5.5.5
All J1708 Data Bus Gauge Pointers (Except the SMC Pointer) Sweep
Probable Cause - J1708 data bus is open between the Engine ECU and the Interface
Module.
Procedure: Follow the steps in Figure 5-15.
Figure 5-15
All J1708 Data Bus Gauge Pointers (except SMC) Sweep
5-30
072-40245 D
5.5.6
All Gauge Pointers Except the SMC Pointer Sweep
Possible Causes - Private bus is open between the Interface Module and the gauges;
Interface Module defective or not receiving power; defective gauge.
Procedure:
1.
Connect the HDT to the diagnostic connector.
2.
Switch the ignition on and verify that the HDT establishes a communications
link with the Interface Module.
3.
a.
If communications are not established, follow the procedures in Figure 5-16 on page 5-31 to determine the cause.
b.
If communications are established, follow the procedures in Figure 517 on page 5-32.
If you have followed the procedures in Figure 5-17 and have not found the
problem, one of the 2-inch gauges could be at fault. To find out which one:
a.
Disconnect the last gauge in the 5-wire cable daisy chain (it will have
an unused connector).
b.
Switch the ignition on and see if the gauges still continue to sweep
after the initialization.
c.
If not, the disconnected gauge is defective. Replace it.
d. If the gauges continue to sweep, switch the ignition off, disconnect
the next to the last gauge in the daisy chain, switch the ignition back
on and observe the pointers.
072-40245 D
e.
Repeat this process until all gauges except the SMC have been unplugged. If the problem goes away after unplugging a particular
gauge, then that gauge is defective and must be replaced.
f.
If the problem persists after unplugging all the gauges, replace the
Interface Module.
5-31
Figure 5-16
Checking Power to the Interface Module
Figure 5-17
Checking Private Bus Wire Continuity
5-32
072-40245 D
6
Using the Handheld Diagnostic Tool
The Handheld Diagnostic Tool (HDT) is designed to be used with the procedures in
Chapter 5 of this manual. This chapter describes the HDT and how to use it. Instrument System troubleshooting information is found in Chapter 5.
The following subjects are covered:
Care and Cleaning
Section 6.1 on page 6-1.
Description
Reading Engine ECU Gauge Data
Reading Private Bus Gauge Data
Viewing the Configuration Data
Programming and Verifying Ports 5A and 5B
Programming the Alarm Point for the Main
Transmission Temperature Gauge Warning LED
HDT Spare Parts
6.1
Care and Cleaning
The HDT is a precision instrument and is designed for years of trouble-free operation
in a normal vehicle repair environment. It will operate between –10 and +50 degrees
Centigrade and is spill-resistant. Always return the tool to its carrying case when not
in use.
To clean the HDT, us only a soft cloth and a mild, non-abrasive soap. Do not use gasoline, alcohol, or solvents because they will damage the instrument and void its
warranty.
072-40245 D
6-1
6.2
Description
The HDT is designed to help troubleshoot the 387 Instrument System by letting you
see the data on the J1708 and private data buses. You will need this tool when installing a new Interface Module.
Connecting the HDT to the diagnostic connector (6- or 9-pin) on the vehicle allows
Engine ECU data on the J1708 data bus to be read and allows the Interface Module to
be programmed. Connecting it to the rear of a 2-inch gauge with the special adapter
allows data on the private data bus to be read. The HDT requires no batteries and is
powered by the vehicle through the connector.
Figure 6-1
Hand-Held Diagnostic Tool
6-2
072-40245 D
6.3
Reading Engine ECU Gauge Data
This section describes how to use the HDT to see gauge data from the Engine ECU on
the J1708 data bus. This is useful while troubleshooting to help determine if the Engine ECU is broadcasting gauge data to the Interface Module and SMC. If no gauge
data is being broadcast, the Engine ECU, the J1708 data bus wiring, or another device
connected to the J1708 data bus could be defective. The HDT can also be used to compare gauge data from the Engine ECU to individual gauge readings in the instrument
system to help determine if the gauge or the Interface Module is defective.
Figure 6-2
6.3.1
Connecting the HDT to the Diagnostic Connector
Procedure
1.
With the ignition off, connect the HDT to the diagnostic connector on the vehicle using the appropriate adapter. See Figure 6-2. The diagnostic connector
is usually located under the dash on the driver’s side.
2.
Turn the ignition on. The HDT will look for the Interface Module and try to
establish communications with it while displaying:
Typically, this takes less than 30 seconds but can take up to 2 minutes.
072-40245 D
6-3
3.
4.
a.
If communications are established, the HDT will display:
b.
If communications are not established after 2 minutes, and repeat
this procedure starting at Step 1 with the ignition off. If the HDT fails
to establish communications after three attempts, there may be a
problem with the J1708 data bus. In this case, pick the symptom from
Chapter 5 that best describes the original failure in the instrument system and follow the troubleshooting procedures.
After communications are established, continue this procedure by pressing
the Select key. While the HDT reads the configuration data, it will display:
a.
If the HDT reads the configuration data successfully, it will display:
b.
If the HDT cannot read the configuration data, it will display
COULD NOT READ THE CONFIGURATION. In this case, first repeat this procedure from Step 1 with the ignition off. If still unsuccessful, one-at-a-time disconnect other devices that use the J1708 data
bus and repeat this procedure each time to isolate the faulty component.
Use the Up and Down keys to move the pointer to NORMAL, then press the
Select key. The HDT will display:
6-4
072-40245 D
072-40245 D
5.
With the pointer at READ PUBLIC BUS, press the Select key. The HDT will
display the following:
6.
To see the names of the J1708 data bus gauges the for which the Interface
Module has been programmed, use the Up and Down keys to scroll through
the list. The J1708 data bus gauge names are: TACHOMETER, ENGINE
LOAD, ENGINE OIL PSI, BOOST PRESSURE, ENG/BRAKESAV OIL TP,
COOLANT TEMPERATURE, and SPEEDOMETER. Other gauge names that
appear are private data bus gauges.
7.
To see the data the Engine ECU is sending to a particular gauge, move the
pointer to that gauge’s name and then press the Select key. After a few seconds the HDT will display the name of the gauge and the value being sent to
it:
a.
If the Engine ECU is broadcasting data for the selected gauge, that
data should appear after VALUE within 15 seconds. This data can be
compared to the corresponding gauge indication.
b.
If data does not appear after 15 seconds, the Engine ECU is not
broadcasting data for the selected gauge. Follow the troubleshooting
procedures.
8.
To select another gauge, press the Return key to exit this display and return
to the gauge list. You can also press the Return key again to go back to previous menus to access other functions.
9.
When finished, disconnect the HDT.
6-5
6.4
Reading Private Bus Gauge Data
This section describes how to use the HDT to see gauge data on the private bus. This
is useful while troubleshooting by determining if the Interface Module is broadcasting data for a particular gauge. If no gauge data is being broadcast for a particular
gauge, the Interface Module may be defective or incorrectly programmed. The HDT
can also be used to compare data from the Interface Module to individual gauge readings in the instrument system to help determine if the gauge or the Interface Module
is defective.
6.4.1
Procedure
1.
Figure 6-3
2.
With the ignition off, connect the HDT to the rear of any 2-inch gauge using
the adapter cable as shown in Figure 6-3. Usually the last gauge in the daisy
chain has an unused connector.
Connecting the HDT to the Private Bus
Typically, this process takes less than 30 seconds.
6-6
072-40245 D
a.
b.
If communications are not established after 15 seconds, repeat this
step. If still unsuccessful there may be a problem with the private
data bus. Choose the symptom from Chapter 5 that best describes the
original instrument system failure and follow the troubleshooting
procedures.
3.
Move the pointer to NAME and press the Select key. The HDT will display:
4.
To see the names of the private data bus gauges the for which the Interface
Module has been programmed, use the Up and Down keys to scroll through
the list.
5.
To see the data the Interface Module is sending to a particular gauge, move
the pointer to that gauge’s name and then press the Select key. After a few
seconds the HDT will display the name of the gauge and the value being sent
to it:
VALUE and LED data should appear within 15 seconds. If not, the Interface Module is not broadcasting data for the selected gauge. If this is the case, follow the
troubleshooting procedures in Chapter 5.
072-40245 D
6.
To select another gauge, press the Return key to exit this display and return
to the gauge list, then repeat this procedure from Step 5.
7.
When finished, disconnect the HDT.
6-7
6.5
Viewing Configuration Data
The HDT can be used to see what conditions turn on the warning lights in non-J1708
gauges. (The information in this section is presented as additional information not
necessary to the operation of the HDT or to the servicing of the vehicle).
6.5.1
Procedure
1.
With the ignition off, connect the HDT to the vehicle’s diagnostic connector
using the appropriate adapter as shown in Figure 6-2. The diagnostic connector is usually located under the dash on the driver’s side.
2.
3.
a.
b.
If communications are not established after 2 minutes, repeat this
procedure starting at Step 1 with the ignition off. If the HDT fails to
establish communications after three attempts, there may be a problem with the J1708 data bus. In this case, choose the symptom from
Chapter 5 that best describes the original instrument system failure
and follow the troubleshooting procedures.
After communications are established, read the configuration data by pressing the Select key. The HDT will display:
a.
6-8
072-40245 D
b.
If the HDT cannot read the configuration data, it will tell you so.
First repeat this procedure from Step 1 with the ignition off. If still
unsuccessful, one-at-a-time disconnect other devices that use the
J1708 data bus and repeat this procedure each time to isolate the
faulty component.
4.
Press the Select key when the pointer is at NORMAL. The HDT will display:
5.
Move the pointer to CONFIGURE and press the Select key. The HDT will display:
6.
To view the configuration data in the Interface Module, move the pointer to
VIEW CONFIG and press the Select key. The HDT will display:
The HDT will a list of J1708 data bus gauge names followed by a list of non-J1708
data bus gauge names. Non-J1708 data bus gauge names will be followed by a
high warning value and a low warning value. The gauge names in the list may
vary with different configurations, and may not reflect the gauge configuration
in the vehicle.
7.
072-40245 D
To see how a gauge’s warning LED is configured, move the pointer to the desired private data bus gauge name and press the Select key. (If a J1708 data
bus gauge name is selected, pressing Select does nothing.)
6-9
6.6
Programming and Verifying Ports 5A and 5B
This section describes how to use the HDT to program and/or verify the programming of Ports 5A and 5B, but only if they are being used as pressure ports. Ports 5A
and 5B only need to be programmed when the Interface Module has been replaced or
if it was found during troubleshooting that the port is incorrectly programmed.
Pressure ports 1A and 1B are always programmed for Air Tank 1 and Air Tank 2 and
cannot be changed with the HDT.
Note:
6.6.1
If the port is already being used as an Air Restriction or Fuel Restriction
port, it cannot be reprogrammed to a pressure port.
Procedure
1.
With the ignition off, connect the HDT to the vehicle’s diagnostic connector
using the appropriate adapter as shown in Figure 6-2. The diagnostic connector is usually located under the dash on the driver’s side.
2.
3.
a.
b.
establish communications after three attempts, a problem may exist
with the J1708 data bus. In this case, choose the symptom from Chapter 5 that best describes the original instrument system failure and
follow the troubleshooting procedures.
After communications are established, read the configuration data by pressing the Select key. The HDT will display:
6-10
072-40245 D
072-40245 D
6-11
a.
b.
First, repeat this procedure from Step 1with the ignition off. If still
J1708 data bus and repeat this procedure each time to isolate the
faulty component.
4.
Press the Select key when the pointer is at NORMAL. The HDT will display:
5.
6.
To change the configuration data in the Interface Module, move the pointer
to MODIFY CONFIG and press the Select key. The display will vary depending upon how the Interface Module is configured. Two examples follow.
6-12
072-40245 D
072-40245 D
6-13
7.
To reprogram a port or to see to which port a gauge is programmed:
a.
Use the Up or Down keys to move the pointer alongside its name.
b.
Press the Select key. The HDT will display:
c.
Press the Up or Down key to scroll through the list of gauge names.
d. When the pointer is next to the name of the gauge you want to assign to the displayed port, press the Select key. (If you want to leave
the port assignment as it was when you started, press the Return key
to return to the previous menu, or simply unplug the HDT.)
e.
8.
After pressing the Select key, the HDT will display the MODIFY
CONFIG menu and the pointer will point to the name of the gauge
you chose:
To keep the changes you have made and store the new configuration data:
a.
Press the Return key to return to the MAIN MENU. The HDT will display:
b.
Move the pointer to WRITE CONFIG and press the Select key. The
HDT will display:
6-14
072-40245 D
The HDT will display the MAIN MENU if the programming was successful. You can then program another gauge or use the Return key to
go back to previous menus. When finished, unplug the tool.
If the HDT displays SYSTEM ERROR, turn the ignition off and back
on, then repeat this procedure from the beginning.
6.7
Programming the Main Transmission Temperature Warning LED
This section describes how to program the correct turn-on temperature of the Main
Transmission Temperature gauge warning LED.This procedure is only required when
the Interface Module has been replaced or a different type of transmission has been
installed in the vehicle.
The temperature at which the warning LED lights depends upon the type of transmission that is installed in the vehicle.
Installed Transmission
6.7.1
Allison without retarder
285° F
Allison with retarder
300° F
ZF transmission
285° F
Manual transmission
275° F
Procedure
1.
With the ignition off, connect the HDT to the diagnostic connector (6- or 9pin) on the vehicle using the appropriate adapter. See Figure 6-2. The diagnostic connector is usually located under the dash on the driver’s side.
2.
3.
a.
072-40245 D
Temperature
6-15
b.
4.
establish communications after three attempts, a problem may exist
with the J1708 data bus. Pick a symptom from Chapter 5 that best
describes the original failure in the instrument system and follow the
troubleshooting procedures.
After communications are established, press the Select key. The HDT will
read the configuration data and display:
a.
b.
First, repeat this procedure from Step 1 with the ignition off. If still
J1708 data bus, repeating this procedure each time to isolate the
faulty component.
5.
With the pointer at NORMAL, press the Select key. The HDT will display:
6.
6-16
072-40245 D
7.
To change the configuration data in the Interface Module, move the pointer
to MODIFY CONFIG and press the Select key. The HDT will display:
8.
Move the pointer to MAIN TRANS TEMP:XXX and press the Select key. The
HDT will display a list of transmissions that may be installed in the vehicle:
9.
Move the pointer next to the name of the transmission type that is installed in
the vehicle, then press the Select key. The HDT will display:
10. Return to the MAIN MENU by pressing the Return key once.
11. Store the Main Transmission Type value in the Interface Module by moving
the pointer to WRITE CONFIG and then pressing the Select key. The HDT will
display:
a.
If the value was successfully stored, the HDT will display the MAIN
MENU. At that point you can use the Return key to go back to previous menus. When finished, unplug the tool.
b.
If instead the HDT displays SYSTEM ERROR, turn the ignition off
and back on, then repeat this procedure from the beginning.
12. When finished, disconnect the HDT from the vehicle.
13. To verify you set the correct value, go to Section 6.5 on page 8.
072-40245 D
6-17
6-18
072-40245 D
6.8
HDT Spare Parts
Part Name
Table 6-1
Part Number
Hand-held Diagnostic Tool, complete kit
000-49856
Handheld Diagnostic Tool
220-12237
Carrying Case
240-12309
Diagnostic Cable with 6-Pin Connector
220-12234
Diagnostic Cable with 9-Pin Connector
220-12233
Private Bus Adapter
240-11204
Reprogramming Cable Adapter
220-12235
HDT Spare Parts
END OF DOCUMENT
072-40245 D
6-19

Model 387 Instrument System Service Manual

Transcription

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